Fountain that flows with fluidic material

ABSTRACT

A fountain for heating and distributing fluidic material is manufactured using various processes and materials so that the fountain is more easily cleaned and sanitized, has improved performance, and is easier to assemble. In one embodiment, the chocolate fountain includes a heating element encased in an aluminum enclosure. A basin containing chocolate is heated by contact with the aluminum enclosure. Because the aluminum enclosure has a relatively high thermal conductivity, the basin is heating substantially uniformly, thus reducing the occurrence of hot spots. Additionally, a plastic auger having a spiral flight rotates and lifts the melted chocolate upward to a top end of cylinder that houses the auger. The use of a plastic auger advantageously eliminates welding artifacts on the auger, such as burrs and pits, on which melted chocolate may accumulate. Accordingly, the plastic auger is easy to clean. A smaller chocolate fountain that may advantageously be more suitable for home use is also described herein.

RELATED APPLICATIONS

This application is a divisional of U.S. application Ser. No.10/698,283, filed Oct. 31, 2003, which is hereby incorporated byreference in its entirety herein.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates generally to a food dispensing apparatus, and moreparticularly to a fountain that flows with a fluidic material.

2. Description of the Related Art

Fondue machines typically include a bowl shaped container for holdingand heating chocolate. The container is heated by a heating element tomelt the chocolate. Fruit, or other food items, may then be dipped intothe container of the fondue machine.

In recent years, fondue machines have taken on alternate configurations.For example, Design & Réalisation Inc. in Montreal, Canada markets achocolate fountain that moves melted chocolate so that it flows over anumber of tiers like a fountain. FIG. 1 is a diagram illustrating aprior art chocolate fountain 100, such as the fountain marketed byDesign & Réalisation Inc. As shown in FIG. 1, the chocolate fountain 100includes a container 110 configured to hold and melt chocolate. A hollowbarrel 120 is mounted in the center of the container 110 and provides apathway for melted chocolate to be moved upward, through its hollowcenter, to the top of the fountain. An auger including a spiral flightextending around the length of the auger is mounted within the hollowbarrel 120. The auger is rotated in order to lift the melted chocolateupward in the hollow barrel 120. On the top of the barrel 120 is a crown140 that fills with chocolate that flows out of the barrel 120. When thecrown 140 is full of melted chocolate, the chocolate begins to fall overthe edges of the crown 140. Attached to the barrel 120 are tiers 130which vary in size. As the chocolate flows downwardly from the crown140, the chocolate flows over each of the tiers 130, thus forming amulti-level chocolate waterfall. The chocolate fountain 100 alsoincludes a heating element that is placed below the container 110.

One disadvantage of the chocolate fountain 100 is the difficulty inattaching the tiers 130 in the appropriate location. For example, thereis no mechanism to easily determine where each of the tiers 130 shouldbe attached to the barrel 120. Additionally, there is no mechanism forensuring that the attached tiers 130 are level so that the meltedchocolate flows evenly around the perimeter of each tier 130.Furthermore, attachment of tiers 130 in the prior art requires the useof tools, such as a hex wrench, in order to tighten a fastener whichsecures the tiers 130 to the barrel 120.

Another disadvantage of the chocolate fountain 100 is the difficultyexperienced in cleaning the various pieces of the fountain 100. Forexample, the tiers 130 and crown 149 are typically manufactured bywelding multiple pieces of metal together, thus leaving burrs, pits, andsharp edges. Because melted chocolate tends to accumulate on anynon-smooth surfaces, cleaning tiers 130 that include burrs, or othernon-smooth welding artifacts, is increasingly difficult. Furthermore,accumulation of chocolate in pits, or other non-smooth surfaces, can beunsanitary. Additionally, the sharp edges created by welding may bedangerous to users of the fountain 100.

A further disadvantage of the chocolate fountain 100 is the unevenheating of the chocolate in the container 110. In particular, thecontainer 110 contains hot spots over the areas that are in directcontact with the heating element. Adding to the problem of unevenheating, the container 110 of the chocolate fountain 100 is notconfigured to urge the chocolate towards a center of the container 110.Accordingly, melted chocolate does not pool in the center of thecontainer 110, but instead spreads on the surface of the unevenly heatedcontainer 110. Additionally, the outer perimeter of the container 110typically becomes hot when the heating element is active, thuspresenting the possibility of harming a user that touches the container.Also, when users of the chocolate fountain 100 dip food items into theflowing chocolate, a portion of the melted chocolate typically fallsoutside of the container 110 due to the small size of the container 110.

Another disadvantage of the chocolate fountain 100 is that as the augerlifts the melted chocolate up the barrel 120, the melted chocolate comesin contact with a central shaft of the auger which requires additionalcleaning. Also, because the auger and the barrel 120 are both made ofmetal, the melted chocolate may be contaminated with metal filingscaused by the contact of the rotating auger with the barrel 120. Inaddition, the friction of the metal auger with the metal barrel 120 mayhaving a sharpening effect on the edges of the spiral flight, causingthe spiral flight to become sharp and dangerous to the user.Furthermore, because the auger is made of metal, with the spiral flightwelded onto a rod, there are typically burrs, pits, and uneven surfacesthat increase the difficulty of cleaning the auger and promote anunsanitary chocolate fountain 100.

Accordingly, what is needed is a chocolate fountain configured for easyattachment of tiers at predetermined locations, such as by including amechanism to easily determine where each of the tiers should be attachedto the shaft. Additionally, what is needed is a mechanism for ensuringthat the attached tiers are level. Furthermore, a chocolate fountainthat allows manual attachment of tiers is desired. Also, a chocolatefountain that is easier to clean is needed. A chocolate fountain thatevenly heats chocolate is also desired. In addition, a chocolatefountain having a container with an outer perimeter that does not gethot when the heating element is active is desired. A chocolate fountainhaving a container that is angled to direct the melted chocolate to thecenter of the container to reduce pooling of stagnant chocolate is alsodesired. Furthermore, a chocolate fountain that reduces the portion ofthe melted chocolate that falls outside of the fountain when users dipfood items into the flowing chocolate is desired. Moreover, a chocolatefountain that reduces the occurrence of contaminants, such as metalfilings, in the chocolate is needed.

SUMMARY OF THE INVENTION

In one embodiment, an apparatus comprises a basin having a bottomsurface and an outer side surrounding the bottom surface, the basinbeing configured to contain a fluidic material within the basin, a highthermal conductivity enclosure substantially encasing a heating element,wherein the enclosure is in contact with the bottom surface of the basinand is configured to substantially evenly heat the bottom surface of thebasin, a cylinder having a top end and a bottom end, wherein the bottomend is attached to the bottom surface of the basin so that the cylinderextends substantially perpendicular from the bottom surface, an augerhaving a spiral flight comprising a plurality of revolutions protrudingalong a length of the auger, wherein the auger is disposed within thecylinder, a tier removably attached to the cylinder and having an uppersurface and a lower surface, and a source of rotation coupled to theauger and configured to rotate the auger inside the cylinder, whereinthe spiral flight supports the fluidic material as the auger rotates,moving the fluidic material upwardly to the top end of the cylinder.

The fluidic material may flow from the top end of the cylinder onto theupper surface of the tier and flows downwardly to the basin. The tiermay be bowl shaped so that an outer perimeter of the tier is curvedtowards the basin. The high thermal conductivity enclosure may comprisealuminum. The revolutions of the spiral flight may have a pitch ofgreater than about 55 mm. The revolutions of the spiral flight may havea pitch of less than about 24 mm. The cylinder may comprise a score markat a predetermined height of the cylinder and extending around an outerperimeter of the cylinder, and wherein the tier is attached to thecylinder at the predetermined height of the cylinder. The score mark maybe of a sufficient depth so that the tier engages the score mark, andwherein the engagement of the tier with the score mark allows theattachment of the tier on the cylinder so that the fluidic materialflows uniformly on a top surface of the tier. The fluidic material maycomprise melted chocolate. The source of rotation may comprise anelectric motor. The electric motor may be mounted so that a drive shaftrotates parallel to the auger and wherein a belt is coupled to the driveshaft and the auger so that the drive shaft rotates the auger. Theelectric motor may be mounted so that a drive shaft directly engages theauger so that the drive shaft rotates the auger. The tier may comprise acollar including a step on a top surface of the collar and a body havingan aperture, wherein the step of the collar is inserted into theaperture and the step is deformed so that the collar is attached to thebody. On the lower surface of the tier, a spot weld may be applied to ajunction of the collar and the body. The tier may comprise a singlestructure. The tier may be removably attached to the cylinder using ahex bolt tightened through a threaded hole in the collar. The tier maycomprise a collar portion, a body portion, and a notch between thejunction of the collar portion and the body portion, and wherein thecylinder comprises a step of sufficient size so that the step engagesthe notch and supports the tier on the cylinder. The auger may comprisea FDA plastic material. The auger may comprise a non-metallic material.The auger may be fabricated by insert molding. An angle between thebottom surface of the basin and the outer perimeter may be less than orequal to about 14 degrees. An angle between the bottom surface of thebasin and the outer side may be greater than or equal to about 16degrees. A diameter of the outer perimeter may be greater than or equalto about 475 mm. A diameter of the outer perimeter may be less than orequal to about 350 mm. A crown may be mounted on the top end of thecylinder, wherein the fluidic material flows from the top end of thecylinder onto the crown and then onto the upper surface of the tier. Asurface of the crown on which the fluidic material flows may besubstantially free of welding artifacts. The crown may be fabricated bymetal casting. The crown may be fabricated by plastic molding. The crownmay comprise a single structure. The crown may be mounted on the top endof the cylinder so that a portion of the crown extends below the top endof the cylinder, and wherein the crown is configured so that the fluidicmaterial does not contact the portion of the crown that extends belowthe top end of the cylinder. The apparatus may further comprise a secondtier mounted on the cylinder, wherein the fluidic material flows on anupper surface of the second tier. The apparatus may further comprise athird tier mounted on the cylinder, wherein the fluidic material flowson an upper surface of the third tier. The apparatus may furthercomprise a handle mounted on the basin. The auger, the crown, and thetier may be free of welding artifacts. The tier may be free of weldingartifacts on the upper surface.

In another embodiment, a method of manufacturing an apparatus forcirculating melted food items comprises molding a plastic auger with aspiral flight, metal casting a crown, providing a structure having acentral aperture, inserting a collar in the central aperture of thestructure, and flanging the collar so that the collar is attached to thestructure. The structure may be concave and the central aperture iscircular. The method may further comprise manufacturing a cylinderhaving a score mark at a predetermined height of the cylinder andextending around an outer perimeter of the cylinder, wherein the collaris attached to the cylinder at the predetermined height of the cylinder.The auger, the crown, and the collar flanged to the structure may besubstantially free of welding artifacts.

In another embodiment, a method of assembling an apparatus forcirculating melted food items comprises mounting a cylinder to a basinso that the cylinder extends substantially perpendicular from a bottomsurface of the basin, placing a tier having a circular aperture on thecylinder so that a top end of the cylinder is inside the circularaperture, and moving the tier towards a bottom end of the cylinder untila locking mechanism stabilizes the tier at a predetermined location andthe tier becomes substantially manually unmovable. The cylinder may betapered so that a diameter of the top end of the cylinder is smallerthan a diameter of a bottom end of the cylinder. The tier may comprise anotch configured to engage a step formed on the outer surface of thecylinder at a predetermined location, the method further comprisingengaging the notch with the step so that the tier is supported on thecylinder and is not manually movable towards the bottom end of thecylinder.

In another embodiment, an apparatus for uniformly heating a materialcomprises a basin configured to contain the material, a cylinderattached substantially perpendicular to the basin and configured tocontain the material, and one or more flexible heating members, whereinthe one or more flexible heating members are coupled to the basin sothat a surface of the basin is substantially uniformly heated. The oneor more flexible heating members may be encapsulated in a heatconductive material. The heat conductive material is a carbon filledrubber.

In another embodiment, an apparatus for uniformly heating a materialcomprises a basin configured to contain the material, a cylinderattached substantially perpendicular to the basin and configured tocontain the material, and a high thermal conductivity enclosuresubstantially encasing a heating element, wherein the enclosure is incontact with the basin and is configured to substantially evenly heatthe basin.

In another embodiment, an apparatus comprises means for containing afluidic material, means for substantially evenly heating a surface ofthe containing means, and means for moving the fluidic material, themoving means having a top end and a bottom end, wherein the bottom endis attached to a bottom surface of the containing means so that themoving means extends substantially perpendicular from the containingmeans, and wherein the fluidic material travels upwardly in the movingmeans to the top end of the moving means and then downwardly to thecontaining means.

In another embodiment, an apparatus comprises a basin having a bottomsurface and an outer side surrounding the bottom surface, the basinbeing configured to contain a fluidic material within the basin, acylinder having a top end and a bottom end, wherein the bottom end isremovably attached to the bottom surface of the basin so that thecylinder extends substantially perpendicular from the bottom surface,and a high thermal conductivity enclosure substantially encasing aheating element, wherein the enclosure is in contact with the bottomsurface of the basin and is configured to substantially evenly heat thebottom surface of the basin. The high thermal conductivity enclosure maycomprise aluminum.

In another embodiment, a fountain comprises a basin configured tocontain a fluidic material, a housing removably attached substantiallyperpendicular to the basin and configured to contain the fluidicmaterial, and a tier removably attached to the cylinder, wherein thetier comprises a collar including a step on a top surface of the collarand a body having an aperture, wherein the step of the collar isinserted into the aperture and the step is deformed so that the collaris attached to the body.

In another embodiment, an apparatus comprises means for heating afluidic material,

means, at least partially extending within the fluidic material, formoving a portion of the fluidic material upwardly within a containedarea, wherein the means for moving includes means for carrying thefluidic material upwardly, and means for manually attaching one or moretiers to the contained area so that the fluidic material flowssubstantially evenly on a surface of the one or more tiers.

In another embodiment, a fountain comprises a basin configured tocontain a fluidic material, wherein a diameter of an outer perimeter ofthe basin is greater than or equal to about 475 mm, a housing removablyattached substantially perpendicular to the basin and configured tocontain the fluidic material, and a moving means configured to move thefluidic material within the basin upwardly within the housing, whereinsubstantially all of the fluidic material returns to the basin, via apath outside of the housing, after the moving means moves the fluidicmaterial to a top of the housing.

In another embodiment, a fountain comprises a basin configured tocontain a fluidic material, a housing removably attached substantiallyperpendicular to the basin and configured to contain the fluidicmaterial, and a plastic auger configured to move the fluidic materialwithin the basin upwardly within the housing, wherein substantially allof the fluidic material returns to the basin, via a path outside of thehousing, after the plastic auger moves the fluidic material to a top ofthe housing.

In another embodiment, a fountain comprises a basin configured tocontain a fluidic material, a housing removably attached substantiallyperpendicular to the basin and configured to contain the fluidicmaterial, and a single structure crown mounted on the top end of thehousing, wherein the fluidic material travels upwardly to the top end ofthe housing, onto the crown, and then downwardly towards the basin. Thecrown may be fabricated by metal casting. The crown may be fabricated byplastic molding.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side elevation view of a prior art chocolate fountain.

FIG. 2 is a cross-sectional side view of a chocolate fountain havingfeatures that reduce cleaning time and improve performance

FIG. 3 is a cross-sectional side elevation view of a single structurecrown.

FIG. 4A is a cross-sectional side elevation view of a tier that may beattached to the cylinder to direct the flow of the melting chocolate.

FIG. 4B is a cross-sectional side view of a cylinder including scoremarks indicating the recommended positions for placing the tiers.

FIG. 5 is a pictoral flow diagram illustrating the assembly of a tierusing a flanging, or riveting, process.

FIG. 6 is a side view of the auger, including a central shaft and aspiral flight.

FIG. 7 is a cross-sectional side elevation view of another embodiment ofa chocolate fountain.

FIG. 8 is a cross sectional side elevation view of an exemplary tierthat may be connected to the cylinder.

FIG. 9 is a cross-sectional side elevation view of a cylinder used tosupport the tiers.

FIG. 10 is a cross-sectional side view of a crown configured forplacement on the top of the cylinder.

FIG. 11 is a top plan view of a flexible heater comprising a pluralityof heating members.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Embodiments of the invention will now be described with reference to theaccompanying Figures, wherein like numerals refer to like elementsthroughout. The terminology used in the description presented herein isnot intended to be interpreted in any limited or restrictive manner,simply because it is being utilized in conjunction with a detaileddescription of certain specific embodiments of the invention.Furthermore, embodiments of the invention may include several novelfeatures, no single one of which is solely responsible for its desirableattributes or which is essential to practicing the inventions hereindescribed.

FIG. 2 is a cross-sectional side view of an improved fountain 200 havingfeatures that address the disadvantages discussed above with respect tothe prior art. The improved fountain 200 advantageously has reducedcleaning requirements, improved performance, and simpler set-up. In oneembodiment, the fountain 200 flows with melted chocolate and istherefore referred to as a chocolate fountain 200. However, whilereference is made herein to the use of chocolate in the fountain 200,the systems and methods described herein are not limited to the use ofchocolate. Accordingly, references made herein to a chocolate fountaindo not limit the fountain to use with chocolate. In particular, anyother fluidic material which a user wishes to circulate through thefountain 200 may be used instead of chocolate. For example, otherconfectionery items, such as caramel, toffee, taffy, or marshmallows;dairy products, such as cheese; or flavorings, such as mint or fruit,may be used in the fountain 200. Additionally, different varieties ofchocolate, such as white chocolate, dark chocolate, or milk chocolate,may be used in the fountain 200. Furthermore, any combination of fooditems, such as a combination of chocolate and caramel, for example, maybe used in the fountain 200.

As shown in FIG. 2, the chocolate fountain 200 comprises a housing 280,upon which a basin 250 is mounted. The housing 280 houses a motor 285and heating elements 260. The motor 285 may be any type of motorsuitable to provide a rotary force. As described in further detailbelow, the heating element 260 is encased in an aluminum enclosure inorder to more uniformly distribute the heat throughout the basin 250.Accordingly, the chocolate is uniformly heated and melted in the basin250 due to the uniform heating of the basin 250 by the heating element260. An auger 240 having a spiral flight 242 surrounding a central shaft244 of the auger 240 is coupled to the bottom surface 252 of the basin250. The motor 285 engages the auger 240 and applies a rotational forcecausing the auger 240 to rotate and thereby to lift melted chocolate,for example, upward inside the cylinder 230, the chocolate travelingupwardly upon the top surface of the spiral flight 242. A crown 210 ismounted on a top 232 of the cylinder 230 and provides an exit locationfor the melted chocolate that has been lifted through the cylinder 230,wherein the melted chocolate flows over a top circumference 212 of thecrown 210. In the embodiment of FIG. 2, an adjustment nut 290 isconnected to the housing 280 and allows adjustment of the height of thefoot so that the fountain 200 may be leveled.

In the embodiment of FIG. 2, the chocolate fountain 200 includes threetiers 220 that are each attached to the cylinder 230. In otherembodiments, any number of tiers 220, such as 1, 2, 4, 5, or 6, forexample, may be attached to the cylinder 230. A top surface of each ofthe tiers 220 comes in contact with the melted chocolate that flows offthe top circumference 212 of the crown 210 so that the melted chocolateflows over each of the tiers 220 and returns to the basin 250. In thisway, the chocolate continues to circulate through the chocolate fountain200 and creates levels of chocolate flowing like a waterfall. Certainaspects of the chocolate fountain 200 will now be described in furtherdetail.

In one embodiment, food items, such as fruit, are dipped into thechocolate flowing downward from the mounted tiers 220 of the fountain200. When the food items are removed from the flowing chocolate, andbefore the chocolate hardens on the food items, drops of chocolate maydrip from the food item. If chocolate drips outside of the fountain 200,cleaning the outside surface of the fountain and/or the surface on whichthe fountain 200 sets may be required. Additionally, chocolate drippedoutside of the fountain 200 is, in most circumstances, contaminated andunusable by the chocolate fountain 200. Thus, dripping chocolate ispreferably caught by the basin 250 so that it may be recirculatedthrough the chocolate fountain 200. In an advantageous embodiment, thediameter of the basin 250 is sufficiently large to capture a significantportion of the dripping chocolate. In one embodiment, the diameter ofthe basin 250 is greater than or equal to about 400 mm. In anotherembodiment, the diameter of the basin 250 is greater than or equal toabout 475 mm. The diameter of the basin 250 may further be increased toany diameter, such as 500, 600, or 1000 mm, for example.

The basin 250 has a bottom surface 252 and sides 254 which areconfigured to hold a fluidic material. In one embodiment, the basin 250is shaped so that the fluidic material flows towards the center of thebasin 250 and is available to circulate up the cylinder 230 on the auger240. In particular, the angle between the bottom surface 252 and thesides 254 is sufficiently large so that the melted chocolate flowstowards the bottom surface 252 and the cylinder 230. Accordingly,because of the shape of the basin 250, pooling of melted chocolate onthe bottom surface 252 is reduced and substantially all of the meltedchocolate circulates through the fountain at a uniform rate. Becausesubstantially all of the chocolate circulates through the fountain 200at a uniform rate, the chocolate is more uniformly heated as it flowsacross the bottom surface 252 of the basin 250. In one embodiment, theangle between the bottom surface 252 and the sides 254 is greater thanor equal to about 13 degrees. In another embodiment, the angle betweenthe bottom surface 252 and the sides 254 is greater than or equal toabout 16. The angle between the bottom surface 252 and the sides 254 mayfurther be increased to 20, 25, 30, or 25 degrees, for example, tomaintain the chocolate on the bottom surface 252 of the basin.

As noted above, the heating element 260 is advantageously encased in analuminum enclosure. Because aluminum has a relatively high thermalconductivity, the aluminum enclosure provides a substantially uniformheating of the bottom surface 252 of the basin 250. In this way, theoccurrence of hot spots, or locations that are heated more than others,is greatly reduced and the chocolate, or other fluidic material in thebasin 250, is uniformly heated. In one embodiment, the aluminumenclosure is sandwiched between layers of another metal. For example, analuminum enclosure may be covered, on a top and/or bottom surface, withstainless steel, thus providing a durable, easy to clean, andnon-reactive surface for interaction with the chocolate and additionallyproviding the high thermal conductivity of the aluminum. Additionally,other metals with high thermal conductivity may be used to encase theheating element 260 in order to provide uniform heating of the basin250. In another embodiment, an aluminum plate, rather than an enclosure,contacts the heating element 260 and the basin 250.

An auger 240 having a spiral flight 242 surrounding a central shaft ofthe auger 240 is coupled to the bottom surface 252 of the basin 250. Abottom end of the shaft 244 includes a connecting means configured toconnect the shaft 244 with the motor 285 so that the motor 285 rotatesthe auger 240. In the embodiment of FIG. 2, the connecting meanscomprises a cross-rod 246 that connects with a gear driven by the motor285. In one embodiment, the diameter of the auger 240, measured from theouter ends of the spiral flight 242, is substantially equal to the innerdiameter of the cylinder 230. Thus, the auger 240 fits snuggly withinthe cylinder 230. As the motor 285 provides a rotational force causingthe auger 240 to rotate, melted chocolate, for example, in the basin 250is moved upwardly along the length of the cylinder 230, traveling uponthe top surface of the spiral flight 242.

In an advantageous embodiment, the spiral flight 242 is angled so thatthe melted chocolate remains on the outer perimeter of the spiral flight242. Additionally, in one embodiment, the spiral flight 242 has anincreased pitch. These features are discussed in more detail below withreference to FIG. 6.

In one embodiment, the crown 210 is a single structure that is formed bymetal casting or plastic molding, for example. Because the crown 210 isa single structure that does not require welding to fabricate, there areno welding artifacts, such as burrs or pits, on the crown 210.Accordingly, without the presence of welding artifacts that mayaccumulate chocolate, the chocolate is easily cleaned from the crown 210and the crown 210 may be easily sanitized. In one embodiment, while thecrown 210 extends over the top 232 of the cylinder 230, the crown 210 iscasted so that the melted chocolate remains in an upper portion of thecrown 210. As such, the crown 210 may be more easily cleaned than thecrowns used in the prior art. These features are discussed in moredetail below with reference to FIG. 3.

Exemplary chocolate fountain 200 includes three tiers 220 that are eachattached to the cylinder 230. A top surface of each of the tiers 220comes in contact with the melted chocolate that flows off the topcircumference 212 of the crown 210 so that the melted chocolate flowsover each of the tiers 220 and returns to the basin 250. Moreparticularly, after the melted chocolate flows over the topcircumference 212 of the crown 210, the chocolate drops to the topsurface of the upper tier 220A. The melted chocolate then flows to anouter perimeter of the upper tier 220A and drops to a lower tier 220B.The melted chocolate next flows to an outside perimeter of lower tier220B and drops to a base tier 220C. The melted chocolate then flows offof the base tier 220C and returns to the basin 250. The returning meltedchocolate flows with the other melted chocolate in the basin 250 andreturns to the bottom surface 252 of the basin so that it may again beheated and lifted through the cylinder 230 by the auger 240. In thisway, the chocolate continues to circulate through the chocolate fountain200 and creates levels of chocolate flowing like a waterfall.

FIG. 3 is a cross-sectional side view of the crown 210. The crown 210includes an aperture 216, through which the cylinder 230 is extended inmounting the crown 210 on the cylinder 230. In one embodiment, the crown210 is supported on the cylinder 230 by fingers 218 extending inwardlytowards a center of the aperture 216. Thus, the fingers 218 of the crown210 rest upon the top 232 of the cylinder 230. In one embodiment, thefingers 218 are extensions of the bottom surface 214, which covers alower cavity 219. Because the finger 218 and the bottom surface 214cover the lower cavity 219, the melted chocolate that flows out of thetop 232 of the cylinder 230 onto the bottom surface 214 of the crown 210does not enter the lower cavity 219. Therefore, cleaning is onlyrequired on the bottom surface 214 and sides of the crown 210.Additionally, in one embodiment the crown 210 is investment casted sothat there are no weld junctions or burrs that increase the complexityof cleaning melted chocolate from the crown 210.

FIG. 4A is a cross-sectional side view of a tier 220 that may beattached to the cylinder 230 to direct the flow of the meltingchocolate. In one embodiment, the tier 220 is attached to the cylinder230 through the use of a connector, inserted and tightened in a cavity226 that extends through a side of the tier 230. More specifically, theaperture 228 of the tier 220 is first placed around the cylinder 230.The tier 220 is then lowered around the cylinder 230 until the desiredposition for the tier is reached. In one embodiment, the cavity 226 isthreaded so that a bolt, such as a hex bolt, may be tightened throughthe cavity 226 against the outside of the cylinder 230. In this way thebolt holds the tier 220 in position on the cylinder 230. In oneembodiment, the tier 220 includes multiple threaded cavities 226 thatmay be used to secure the tier 220 to the cylinder. Additionally, othertypes of attachment devices known in the art may be used to secure thetier 220 to the cylinder 230. In an embodiment using multiple tiers 220,such as that illustrated in FIG. 2, each tier 220 may have apredetermined position on the cylinder 230.

The exemplary tier 220 includes a collar 222 connected to the a body221. In an advantageous embodiment, rather than welding the collar 222to the body 221 (which would result in weld joints and burrs whichincrease the difficulty of cleaning each of the tiers 220) the collar222 is flanged to the body 221. This process, described further belowwith respect to FIG. 5, flanges an extrusion of collar 222 formingflange 224 and mounting the collar 222 onto the body 221.

FIG. 4B is a cross-sectional side view of a cylinder 230 including scoremarks 234 indicating predetermined positions for placing the tiers 220.In one embodiment, each of the score marks 234 extend around the entireperimeter of the cylinder 230. The score marks 234 advantageously allowthe user to easily determine the appropriate position for each of thetiers 220. For example, a tier 220 may be lowered until the cavity 226is aligned with a score mark 234, after which a bolt may be tightened sothat the tier 220 is attached around the score mark 234. Also, the scoremarks 234 on the cylinder 230 advantageously allow the level placementof the tiers 220 without the need of leveling equipment. Moreparticularly, the score marks 234 are placed parallel to the top 232 ofthe cylinder 230 so that tiers 220 are level when they are aligned withthe score marks 234.

In one embodiment, the score marks 234 form a groove of sufficient depthto engage the tier 220 and provide a support for leveling the tier 220on the cylinder 230. More particularly, the score marks 234 may be ofsufficient depth so that as a tier 220 is moved over the score marks 234the tier 220 engages with the score marks 234. In this way, thepredetermined locations for each of the tiers 220 may be easilyidentified. In one embodiment, the attachment of the tiers 220 in alevel orientation, such that the fluidic material flows evenly over thesurface of the tiers 220, is also possible because of the interaction ofthe tiers 220 with the grooves of the score marks 234. For example, inone embodiment the tightening bolts may be tightened so that they extendthrough the cavity 226 of the tier into the groove of the score mark234. Thus, attachment of the tiers 220 in a level orientation may beaccomplished by simply attaching the tightening bolts so that theycontact the score marks 234.

FIG. 5 is a pictoral flow diagram illustrating the assembly of a tier220 using the above-described flanging, or riveting, process. In step510, a plate sheet of metal is acquired to be formed into the body 221of a tier 220. Through a drawing process, the plate sheet is shaped intoa bowl shaped structure as shown at step 530. The bowl-shaped structureis then trimmed, as shown in step 540, to include an aperture 228,through which the collar 222 may be attached.

In step 520, a tube is provided for manipulation and use as the collar222. At step 550, the collar 222 is formed by cutting the tube to theappropriate height and machining the tube so that a circular extrusion223 extends from an inner circumference of the tube. The collar 222 andthe body 221 are then assembled in step 560. In an advantageousembodiment, assembly comprises inserting the collar 220 into theaperture of the trimmed plate sheet so that the extrusions extend insidethe body 221. In step 570, the extrusions are deformed so that theyextend over a portion of the body 221, thus attaching the collar 222 tothe body 221 without the use of welding. In one embodiment, theextrusions are pressed so that the junction between the extrusions andthe body 221 is substantially smooth. In one embodiment, one or morespot welds may be applied to the junction between the extrusions and thebody 221 in order to reinforce the connection between the body 221 andthe collar 220. In this embodiment, the spot welds are applied to theside of the body 221 upon which melted chocolate does not flow over.Because the melted chocolate does not flow over the spot welds, thereinforcement of the connection between the body 221 and the collar 220with spot welds does not increase the complexity of cleaning thefountain 200.

FIG. 6 is side view of the auger 240, including central shaft 244 andspiral flight 242. As shown in FIG. 6, the incline angle of the spiralflight 242, as shown on revolution 242A, is about 25 degrees. Theincline angle of the spiral flight 242 is selected so that the chocolatetravels upwardly as the auger 240 rotates. In one embodiment, when themelted chocolate travels upwardly in the cylinder 230 on the surface ofthe spiral flight 242, the incline angle is such that the chocolate doesnot contact the shaft 244 of the auger 240. Because the chocolate doesnot contact the shaft 244, there is less surface area of the auger 240,including the shaft 244 between revolutions of the spiral flight 242, toclean after use of the chocolate fountain 200. Additionally, a distance(pitch) between revolutions of the flight 242 is increased so that theincreased incline angle is possible.

In one embodiment, the auger 240 is plastic and is fabricated using amolding process, such as an injection molding process. In one exemplaryembodiment, the auger 240 is insert molded. Because the auger 240 ismade of plastic fabricated using a molding process, for example, thereare no weld spots, pits, burrs on the auger 240. Accordingly, the numberof non-smooth areas (that collect melted chocolate) on the auger 240 isreduced and the auger 240 is advantageously more easily cleaned thanthose in the prior art. Additionally, because the auger 240 is plastic,contact of the rotating auger 240 against the inner surface of thecylinder 230 does not create metal filings and prevents the auger 240from becoming sharp and harmful to the user. Thus, the auger 240advantageously reduces contamination caused by contact of the auger 240with the cylinder 230. In other embodiments, the auger 240 comprisesother materials that are easy to clean and/or reduce the occurrence ofcontaminants that are mixed into the fluidic material due to frictionbetween the auger 240 and the cylinder 230.

FIG. 7 is a cross-sectional side view illustrating another embodiment ofa chocolate fountain. The chocolate fountain 700 illustrated in FIG. 7is smaller than the chocolate fountain 200 and, accordingly, may be moresuitable for home use. The chocolate fountain 700 is advantageously easyto assemble, operate, and clean.

The fountain 700 includes a basin 750 mounted on a housing 780. In oneembodiment, the basin comprises a material with a high thermalconductivity, such as aluminum, for example. Additionally, in oneembodiment, an aluminum basin may be coated with one or more non-stickmaterials, such as teflon. As described further below with reference toFIG. 11, in one embodiment a flexible heater may be attached to thebottom of the basin 750. In this embodiment, because the basin 750comprises a high thermal conductivity material, a power requirements ofthe flexible heater may be reduced.

As illustrated in FIG. 7, the housing 780 includes a bottom cover 782.In one embodiment, the bottom cover 782 includes an access panel thatmay be opened to access the inside of the housing 780. In this way, thecomponents within the housing 780 may be easily accessed and repaired.In another embodiment, other portions of the fountain 700 include accesspanels that allow the user or technician to easily access and/or repairthe components within the housing 780. The fountain 700 also includesone or more handles 790 that allows the user to easily move the entirefountain 700 or a portion of the fountain 700, such as the housing 780and basin 750.

Similar to the chocolate fountain 200 discussed above, the fountain 700includes a cylinder 730 attached to the basin 750 that houses an auger740 configured to support a fluidic material as it is lifted upwardlythrough the cylinder 730. In the embodiment of FIG. 7, a motor 785 ismounted in the housing 780 so that the auger 740 is directly driven bythe motor 785. Accordingly, the connection between the motor 785 and theauger 740 does not require additional gears or belts, reducing thenumber of parts required for the fountain 700.

FIG. 8 is a cross sectional side view of an exemplary tier 720 that maybe connected to the cylinder 730. The tiers 720 (including top tier 720Aand bottom tier 720B) are mounted on the cylinder 730 and provide asurface on which the fluidic material may flow. For example, in oneembodiment, the tiers 720 are metal and are fabricated according to themethod described with respect to FIG. 5. Alternatively, as illustratedin FIG. 8, the tiers are a single structure, formed by metal casting,metal drawing, or plastic molding, for example. Accordingly, the tiers720 do not require welding and, thus, do not have any welding artifacts,such as burrs or pits, that may retain melted chocolate and increase thecomplexity of cleaning the tiers 720. Also, the tiers 720 may be formedof plastic using a molding process, such as injection molding. Whilespecific methods of manufacturing the tiers 720 are discussed above, itis expressly contemplated that the tiers 720 may be fabricated in anyother way known in the art. The fountain 700 includes two tiers 720,namely tiers 720A and 720B. In other embodiment, the fountain 700 may beconfigured to support any number of tiers, such as 1, 3, 4, 5, or 6tiers, for example.

As illustrated in FIG. 8, the tier 720 includes an aperture 728, throughwhich the cylinder 730 is mounted. More particularly, the tier 720 ismounted on the cylinder 730 by first placing the tier 720 on the upperend 732 of the cylinder 730. The tier 720 is placed on the cylinder 730so that the cylinder 730 extends through the aperture 728 of the tier720. The tier 720 is then moved down the length of the tier 720 untilthe desired location for the tier 720 is reached. In one embodiment,each of the tiers 720, such as tiers 720A and 720B, have differentdiameters. For example, the chocolate fountain 700 (FIG. 7) illustratesthe tier 720A having a smaller diameter than tier 720B. Additionally,the apertures 728 of tiers 720 may have different diameters. Asdiscussed in detail below (FIG. 9), because the tiers 720 have apertures728 of different diameters, the location of the tiers 720 on thecylinder 730 may be easily determined by simply sliding each tier 720down the cylinder 730 until the tier 720 locks in to a predeterminedlocation on the cylinder 730.

In one embodiment, the tier 720 includes a notch 725 on the innersurface of the tier 720. The notch 725 is configured to engage thecylinder 730 so that the tier 720 is supported on the cylinder 730without the need for an additional tightening mechanism. In oneembodiment, the notch 725 is molded as part of the tier 720. In anotherembodiment, the notch 725 is etched into the tier 720 after molding thetier 720.

FIG. 9 is a cross-sectional side view of a cylinder used to support thetiers 720. In one embodiment, the cylinder 730 is tapered so that adiameter of the upper end 732 of the cylinder 730 is smaller than adiameter of the lower end 734 of the cylinder 730. Because the cylinder730 is tapered, tiers 720 having apertures 728 with different diameterswill each fittingly engage the cylinder 730 at different positions ofthe cylinder 730. For example, in one embodiment, the bottom tier 720Bhas an aperture with a diameter that is substantially equal to adiameter of the cylinder 730 at position 730B. Accordingly, the tier720B engages with the cylinder at position 730B so that the tier 720B ismanually mounted on the cylinder 730. Similarly, the top tier 720A hasan aperture with a diameter that is substantially equal to a diameter ofthe cylinder 730 at position 730A. Thus, the tier 720A engages with thecylinder at position 730A so that the tier 720A is manually mounted onthe cylinder 730. In this way, the tiers 720 may be manually mounted onthe cylinder 730.

In another embodiment, the cylinder 730 includes one or more ledges 731configured to engage with tiers 720 in mounting the tiers 720 on thecylinder 730. In one embodiment discussed above, the tier 720 includes anotch 725 which is configured to engage with the ledge 731 in mountingthe tier 720 on the cylinder 730. With reference to the cylinder 730(FIG. 9), the ledge 731A has a larger diameter than ledge 731B.Accordingly, a tier 720 having an aperture with a diameter larger thanthe diameter of ledge 731A may be mounted at a lower location 730A, suchas location 730B, on the cylinder 730.

FIG. 10 is a cross-sectional side view of a single structure crown 710configured for placement on the top of the cylinder 730. The crown 710includes an aperture 716 configured to fit over the upper end 732 of thecylinder 730. In one embodiment, the crown 710 is supported on thecylinder 730 by a tier 720, such as tier 720A (FIG. 7). As discussedabove, the tiers 720, such as tier 720A, for example, may be mounted onthe cylinder 730 using various mounting mechanisms. After the tier 720A,for example, is mounted on the cylinder 730, the tier 720A is stabilizedand may support a further structure. Accordingly, the crown 710 may bepositioned on the cylinder 730, with the aperture 716 surrounding thecylinder, so that a lower surface 712 of the crown 710 is supported bythe tier 720A. In this way, the number of required parts needed to mountthe crown 710 is reduced.

FIG. 11 is a top view of a flexible heater 760 comprising at least oneheating member 764. In one embodiment, the flexible heater 760 comprisesmultiple heating members 764. In the embodiment of FIG. 11, multipleheating members 764 are concentric, that is, each of the heating members764 has a common center. In another embodiment, multiple heating members764 are arranged in other configurations, such as in a web or a gridpattern, for example. In an advantageous embodiment, the flexible heater760 is encapsulated in flexible heat conductive medium, such as rubber.For example, a filled rubber, such as a carbon filled rubber, may beused to encapsulate the flexible heater 750. Thus, the flexible heater750 advantageously may be attached directly to a non-planar surface andprovide substantially uniform heating of the surface. In an advantageousembodiment, each of the heating members 764 provides a heat sourcecapable of transferring heat. The flexible heater is advantageouslyattached to the bottom of the basin 750 and provides substantiallyuniform heating of the basin 750. In this way, the occurrence of hotspots, or locations that are heated more than others, is greatly reducedand the chocolate, or other fluidic material in the basin 750, isuniformly heated.

The foregoing description details certain embodiments of the invention.It will be appreciated, however, that no matter how detailed theforegoing appears in text, the invention can be practiced in many ways.As is also stated above, it should be noted that the use of particularterminology when describing certain features or aspects of the inventionshould not be taken to imply that the terminology is being re-definedherein to be restricted to including any specific characteristics of thefeatures or aspects of the invention with which that terminology isassociated. The scope of the invention should therefore be construed inaccordance with the appended claims and any equivalents thereof.

1. A method of manufacturing an apparatus for circulating melted fooditems, the method comprising: molding a plastic auger with a spiralflight; forming a crown; providing a structure having a centralaperture; inserting a collar in the central aperture of the structure;and flanging the collar so that the collar is attached to the structure.2. The method of claim 1, wherein the structure is concave and thecentral aperture is circular.
 3. The method of claim 1, furthercomprising manufacturing a cylinder having a score mark at apredetermined height of the cylinder and extending around an outerperimeter of the cylinder, wherein the collar is attached to thecylinder at the predetermined height of the cylinder.
 4. The method ofclaim 1, wherein the auger, the crown, and the collar flanged to thestructure are substantially free of welding artifacts.
 5. The method ofclaim 1, wherein the crown is formed by injection molding.
 6. The methodof claim 1, wherein the crown is formed by metal casting.
 7. The methodof claim 1, wherein the plastic auger is fabricating using an insertmolding process.
 8. A method of assembling an apparatus for circulatingfluidic material, the method comprising: coupling a cylinder to a basinso that the cylinder extends substantially perpendicular from a bottomsurface of the basin; placing a tier having a circular aperture on thecylinder so that a top end of the cylinder is inside the circularaperture; and moving the tier towards a bottom end of the cylinder untila locking mechanism stabilizes the tier at a predetermined location andthe tier is supported on the cylinder by the locking mechanism.
 9. Themethod of claim 8, wherein the cylinder is removably coupled to thebasin.
 10. The method of claim 8, wherein the cylinder comprises a stepconfigured to engage the tier as the tier is moved towards a bottom endof the cylinder.
 11. The method of claim 8, wherein the cylindercomprises a groove extending around a perimeter of the cylinder at thepredetermined location.
 12. The method of claim 8, further comprisingattaching an auger to a source of rotation disposed proximate the basinso that the auger is positioned in a longitudinal cavity in the centerof the cylinder.
 13. The method of claim 12, wherein the auger comprisesplastic.
 14. The method of claim 8, wherein the fluidic materialcomprises melted chocolate.
 15. The method of claim 12, furthercomprising placing a crown on a top end of the cylinder, wherein thefluidic material is moved upwardly in the cylinder by the auger withinthe cylinder and the fluidic material flows over a top surface of thecrown.
 16. The method of claim 15, wherein the crown comprises a plasticsingle structure crown.
 17. A method of assembling a chocolate fountaincomprising: removably coupling a housing having a central aperture to abasin so that the housing extends longitudinally substantiallyperpendicular from a bottom surface of the basin, the basin beingconfigured to contain chocolate; placing a tier having a circularaperture on the housing so that a top end of the housing is inside thecircular aperture; and moving the tier towards a bottom end of thehousing until a support structure positioned at a predetermined locationof the housing is engaged by the tier such that the support structuresupports the tier at the predetermined location.
 18. The method of claim17, wherein the support structure comprises a step integrally formed inthe housing.
 19. The method of claim 17, wherein the support structurecomprises a groove extending around a perimeter of the housing.
 20. Themethod of claim 17, wherein the housing is substantially cylindrical.